Reusable packaging system

ABSTRACT

A reusable packaging system is disclosed in which a series of thermoformed trays are used to mount six spider type office chair bases. Three bases are mounted in an inverted position on the tray and three bases are mounted upright. A stack of load trays may be constructed with the bottom-most tray fastened to a standard pallet. The stack is plastic wrapped and shipped. After unloading, empty trays may be stacked in a nested arrangement and returned for reuse making for a simple, reliable and inexpensive system.

This application is a continuation of application Ser. No. 10/307,742,filed on Dec. 2, 2002, entitled “Reusable Packaging System”, andapplicants claim the benefit of the filing date thereof.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a reusable packaging system and moreparticularly to a reusable packaging system for spider-type chair baseswith each base having a hub and five spokes where the system includessupport trays having about the same length and width as a standardpallet.

2. Description of the Related Art

Packaging systems have been in existence for many years includingpackaging systems for handling multiple items bundled together. See forexample U.S. Pat. Nos. 758,239; 819,259; 3,910,411; 4,088,225;4,170,297; and 6,056,121.

Packaging frequently concerns itself with enclosing an item or items tobe transported in the smallest volume consistent with item protection.Another consideration is the ability to stack packaged items on astandard pallet so that the packaged items can be easily moved by aforklift truck. By standard pallet, it is meant a pallet having lengthand width dimensions of about 42 inches by about 48 inches.

Spider-type chair bases are particularly difficult to efficientlypackage because of their awkward shape.

BRIEF SUMMARY OF THE INVENTION

Difficulties previously encountered have been overcome by the presentinvention. What is described here is a reusable packaging system formultiple items of similar shape comprising a plurality of trays, eachtray having a central panel, a peripheral skirt and a top surface with aplurality of recesses for receiving a first plurality of items in afirst position and a plurality of mounds for receiving a secondplurality of items in a second position, the second position beingopposite to that of the first position. The trays are stacked upon oneanother in the same orientation with plurality of items being sandwichedbetween trays so as to alternate with the trays when the reusablepackaging system is used to transport the items and the trays arenestable with one another when the trays are not being used to transportitems.

There are a number of advantages, features and objects achieved with thepresent invention which are believed not to be available in earlierrelated devices. For example, one advantage is that the presentinvention provides a packaging system that is especially suited for theefficient transport of six spider-type chair bases per support traywithin the dimensional perimeters of a standard pallet where as many asseven or eight trays may be bundled together. Another object of thepresent invention is to provide an efficient packaging system thatallows empty trays to be nested and returned for reuse. A furtheradvantage of the present invention is that the packaging system isrelatively inexpensive, easy to use and very efficient.

A more complete understanding of the present invention and otherobjects, advantages and features thereof will be gained from aconsideration of the following description of a preferred embodimentread in conjunction with the accompanying drawing provided herein. Thepreferred embodiment represents an example of the invention which isdescribed here in compliance with Title 35 U.S.C. section 112 (firstparagraph), but the invention itself is defined by the attached claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is an elevation view of a spider-type chair base.

FIG. 2 is a top plan view of the chair base illustrated in FIG. 1.

FIG. 3 is an isometric view of a support tray.

FIG. 4 is a top plan view of the tray illustrated in FIG. 3.

FIG. 5 is a partial sectional view taken along line 5-5 of FIG. 4.

FIG. 6 is a partial sectional view taken along line 6-6 of FIG. 4.

FIG. 7 is an upward looking isometric view of the tray illustrated inFIGS. 3-6.

FIG. 8 is a downward looking isometric view of a tray on which ismounted six chair bases.

FIG. 9 is an isometric view of a standard pallet.

FIG. 10 is an elevation view of a stack of seven trays, each with sixchair bases.

FIG. 11 is a stack of trays and bases as illustrated in FIG. 10 but witha plastic wrap, a layer of plywood and strapping bands.

FIG. 12 is an elevation view of a stack of nested trays.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

While the present invention is open to various modifications andalternative constructions, the preferred embodiment shown in the variousfigures of the drawing will be described herein in detail. It isunderstood, however, that there is no intention to limit the inventionto the particular embodiment, form or example disclosed. On thecontrary, the intention is to cover all modifications, equivalentstructures and methods, and alternative constructions falling within thespirit and scope of the invention as expressed in the appended claims,pursuant to Title 35 U.S.C. section 112 (second paragraph).

As an introduction to what is disclosed here, reference is made to FIGS.1 and 2 which illustrate a spider-type chair base 10. The chair baseincludes a central cylindrical hub 12 and five legs or spokes 14, 16,18, 20, 22. A caster (not shown) is attached at the extended end of eachspoke. In turn, the chair base forms the lower portion of an office orwork chair, such as that disclosed co-pending application Ser. No.10/077,409, assigned to the assignee of the present application.

Chair bases may be manufactured or finished at a location distant froman assembly location where a chair base is mated with an upper portionof a chair. Generally the chair bases are cast in a casting shop at adistance from the chair assembly location. The chair bases may then beshipped to a polishing location and from there to the assembly locationor to a paint location. From the paint location, the chair bases areshipped to the assembly location for chair completion. During eachshipment, it is desirable that the chair bases be handled so as not tomar the surface finish of the bases.

To accomplish transportation of chair bases efficiently andeconomically, a system has been developed which includes the use ofsupport structures, such as thermoformed trays. One such tray 24 isillustrated in detail in FIGS. 2-7. Each tray includes a central panel25 with a top surface 26, a bottom surface 27 and a depending peripheralskirt 28. Formed in the top surface 26 are arrays of receivingstructures, such as a plurality of recesses and a plurality of mounds.It is apparent that some of the recesses in plan view have theconfiguration of a chair base, namely, a central recess and fiveradiating recesses. There are three such arrays, such as five pointed“star” recesses 30, 32, 34, in a generally triangular relationship witheach other. Each of the star recesses include a central, cup-like,cylindrical recess 36, 38, 40. Radiating from the central recess 36 ofthe star recess 30 are five elongated spoke recesses 42, 44, 46, 48, 50.Radiating from the central recess 38 of the star recess 32 are fivespoke recesses 52, 54, 56, 58, 60. Extending from the central recess 40of the star recess 34 are five spoke recesses 62, 64, 66, 68, 70. Thetriangular relationship may be visualized in FIG. 4 when a line isimagined between the recesses 36 and 38, another line imagined betweenthe recesses 38 and 40, and a third line imagined between the recesses36 and 40. It should also be noted that as shown in FIG. 4 the starrecesses 30 and 32 are generally aligned rotationally, but that the starrecess 34 is not aligned. The star recess 34 is disposed rotationallyslightly more in a clockwise direction than the star recesses 30 and 32.

The top surface 26 also includes three cup-like recesses 80, 82, 84.Each of the cup-like recesses are related to five generally circularmounds forming an array of receiving structures. For example, thecup-like recess 80 is related to a first group of five circular mounds90, 92, 94, 96, 98. The cup-like recess 82 is related to a second groupof five mounds 100, 102, 104, 106, 108. The third cup-like recess 84 isrelated to a third set of five mounds 110, 112, 114, 116, 118. Referringagain to FIG. 4, another relationship may be visualized by imaginingthree lines connecting the recesses 80, 82, 84 in triangular fashion aswas done with the recesses 34, 36, 38. Furthermore, as with the starrecesses 30, 32, 34, the three recesses 80, 82, 84 and theircorresponding five mounds arc not rotationally aligned. The arrayincluding the recess 82 and corresponding mounds 100, 102, 104, 106, 108is shown rotated slightly more clockwise than are the arrays of recesses80, 84, and their corresponding mounds; this relationship may bevisualized by drawing imaginary lines between the recess 80 and themound 90 and between the recess 84 and the mound 110, and comparingthose lines with an imaginary line from the recess 82 to the mound 100.

Three reinforcing recesses 120, 122, 124 are also found in the topsurface 26 near the periphery to stiffen the tray. The bottom surface 27of the tray 24, FIG. 7, has the opposite sides of the star recesses 30,32, 34 (with the cupike recesses 36, 38, 40) and the cup-like recesses80, 82, 84 and appear as downwardly extending projections 30 a, 32 a, 34a, 36 a, 38 a 40 a, 80 a, 82 a, 84 a, respectively.

The first group of star recesses 30, 32, 34 are configured to receivethree chair bases of the type shown in FIGS. 1 and 2 in which the chairbases are disposed in a first or inverted position. The second group ofcup-like recesses 80, 82, 84 and related groups of five mounds 90, 92,94, 96, 98; 100, 102, 104, 106, 108; and 110, 112, 114, 116, 118 receivethree chair bases in a second or upright disposition. The trays areformed of high density polyethylene having a nominal thickness of about0.100 inches. The starting thickness of the polyethylene sheet, beforeforming, is about 0.187 inches. A resilient strip 126, FIG. 4, may beused in the spoke recesses, such as the recess 52, if further cushioningis desired for the inverted bases.

An example of a base loaded tray is illustrated in FIG. 8. Six mountedchair bases are shown with three of the chair bases 132, 134, 136 beingin an inverted position and three chair bases 138, 140, 142 beingdisposed upright in a position exactly opposite to the position of thefirst mentioned group of chair bases. The chair base 132 includes a hub250 and five legs 252, 256, 256, 258, 260; the chair base 134 includes ahub 262 and five legs 264, 266, 268, 270 272; and the chair base 136includes a hub 274 and five legs 276, 278, 280, 282, 284. The chair base138 includes a hub 286 and five chair legs 288, 290, 292, 294, 296; thechair base 140 includes a hub 298 and five legs 300, 302, 304, 306, 308;and the chair base 142 includes a hub 310 and five legs 312, 314, 316,318, 320. Also, as shown in FIG. 8, the inverted chair bases 132, 134,136 are supported in the tray 24 by having tops of the hubs and upperportions of the legs disposed in the star recesses 30, 32, 34,respectively. For example, the hub 250 of the chair base 132 is locatedin the recess 36 and the legs 252, 254, 256, 258, 260 of the chair base132 arc located in the spoke recesses 42, 44, 46, 48, 50, respectively.The hub 262 of the chair base 134 is located in the recess 38 and thelegs 264, 266, 268, 270, 272 are located in the spoke recesses 52, 54,56, 58, 60, respectively. The hub 274 of the chair base 136 is locatedin the recess 40 and the legs 276, 278, 280, 282, 824 are located in thespoke recesses 62, 64, 66, 68, 70, respectively. As also shown in FIG.8, the upright chair bases 138, 140, 142 are supported in the tray 24 byhaving bottoms of the hubs and extended ends of the legs in the cuplikerecesses 80, 82, 84, respectively and their respective circular mounds.For example, the hub 286 of the chair base 138 is located in thecup-like recess 80 and the extended ends of the legs 288, 290, 292, 294,296 are disposed, respectively, in the mounds 90, 92, 94, 96, 98. Thehub 298 of the chair base 140 is located in the cup-like recess 82 andthe extended ends of the legs 300, 302, 304, 306, 308 are disposed inthe circular mounds 100, 102, 104, 106, 108, respectively. The hub 310of the chair base 142 is located in the cuplike recess 84 and theextended ends of the legs 312, 314, 316, 318, 320 are disposed in thecircular mounds 110, 112, 114, 116, 118, respectively.

Illustrated in FIG. 9 is an example of a standard pallet 150 having adepth dimension represented by the line 152 of about forty-eight inchesand a width dimension represented by the line 154 of about forth-twoinches. For handling and shipping, the loaded trays are stacked to aheight of about sixty-five to seventy-two inches or from between six tonine loaded trays.

The height of the stack is usually a function of ease of loading andunloading and the size of the truck used for transportation.

There is illustrated in FIG. 10 a stack of trays 158 including a bottomtray 160 connected to the pallet 150 and six additional loaded trays161, 162, 163, 164, 165, 166. As can been seen, the trays are eachaligned in the same orientation as are the chair bases. The bottom tray160 may be attached by screws (not shown) to a length of two by fourwood 167 which in turn is bolted (not shown) to the pallet. Each stackedtray (above the lowest tray) is supported by the hubs of the chairbases. For example, the hubs 250, 262, 274, 286, 298, 310, FIG. 8,support the next higher stacked tray. In particular the weight of eachloaded tray is transmitted to the hubs of the chair bases of the traybelow. When a chair base is inverted, such as the chair bases 132, 134,136, FIG. 8, the five legs or spokes are cradled by the five recesses ofthe supporting tray, such as the recesses 62, 64, 66, 68, 70, FIG. 4,and the bottoms of the hubs, such as the hubs 250, 262, 274, arecaptured by projections of the next higher trays, such as theprojections 36 a, 38 a, 40 a, FIGS. 5, 6 and 7. With regard to theupright chair bases, such as the chair bases 138, 140, 142, FIG. 8, thebottom portions of the hubs are captured in the cup-like recesses, suchas the recesses 80, 82, 84, FIGS. 3-6 and 8, and the top portions of thehubs, such as the hubs 286, 298, 310, FIG. 8 are captured by projectionsof the next higher trays, such as projections 80 a, 82 a, 84 a, FIGS. 5and 7. This supports the next tray and constrains the chair bases.

The arrangement of a tray and six chair bases, three inverted, threeupright, is repeated so that a stack of six to nine but more likelyseven or eight layers of chair bases are arranged on a pallet as shownin FIG. 10. A plywood sheet 170, FIG. 11, may be placed across the topor uppermost layer of chair bases and then the stack may be shrinkwrapped with a plastic film 172. Steel or plastic bands 180, 182, mayalso be used or may be used instead of a plastic wrap. Another pair ofbands, not shown, may be placed perpendicular to the first mentionedbands 180, 182. A preferred arrangement is simply to wrap the stack withplastic only. The plywood and strapping bands may not be needed.

Reference is now made to FIG. 12 where there is illustrated a stack 190of empty trays. After shipment of chair bases, the trays are returnedfor reuse. On the return trip the trays are nested one within another ontop of the pallet 150 as shown. Because there are no longer layers ofchair bases, as many as twenty trays 195, 196, 197, 198, 199, 200, 201,202, 203, 204, 205, 206, 207, 208, 209, 210, 211, 212, 213, 214 may bestacked, banded and returned to the chair base casting company, forexample, or to the paint and/or polishing company for reuse.

In operation a metal casting or a polisher or a painting company loadssix chair bases on a single tray with three of the chair bases beinginverted and three of the chair bases being upright as shown in FIG. 8.A tray attached to a pallet acts as a bottom layer of alternating traysand chair bases. After the bottom or lower most tray is loaded withbases, a second tray is positioned over the bottom tray and is loadedwith bases. The trays are stacked so that the chair bases are sandwichesbetween two trays. Each of the trays are in exactly the same orientationor alignment so that the six chair bases are constrained, both by alower tray to which the chair bases are mounted and by the next uppertray which also engages the same chair bases with its bottom surface.Each tray is positioned on top of six chair bases and loaded with itsown six bases. This process continues until seven or eight alternatinglayers of trays and chair bases are formed. At seven or eight layers ofchair bases the stacked trays and chair bases stand approximatelybetween sixty-five to seventy-two inches from the bottom of the palletto the uppermost tray. Thereafter, a plastic wrap is placed around thestack. A piece of plywood may be placed over the uppermost group ofchair bases and metal or plastic strapping bands may also be used tosecurely fasten the stack together. After the stack is secured, theentire stack is in a stable condition and it may be moved by a fork lifttruck to a vehicle for transporting the chair bases to a distantlocation. It is noted that already loaded trays may be stacked ifdesired.

The trays are constructed with a slanted peripheral skirt so as to nestone on top of another as shown in FIG. 12 after the chair bases havebeen unloaded. In this mode approximately twenty trays may be loaded ona pallet and banded for a return trip thereby allowing the trays to bereused for future shipments of chair bases. In this fashion a reliableand efficient packaging system is arranged which is also inexpensivebecause the trays, bands and pallets may used repeatedly.

The above specification describes in detail a preferred embodiment ofthe present invention. Other examples, embodiments, modifications andvariations will, under both the literal claim language and the doctrineof equivalents, come within the scope of the invention defined by theappended claims. For example, more or less trays may be used in a stack,perhaps as a function of the vertical height of the chair base beingtransported; a plastic wrap may be used around the stack instead ofbands or perhaps in addition thereto and it may be found that the upperplywood sheet can be dispensed with. These are all considered equivalentstructures and will also come within the literal language of the claimsas will other alternatives and many new technologies. There is no desireor intention here to limit in any way the application of the doctrine ofequivalents nor to limit or restrict the scope of the invention.

1. A reuseable packaging system comprising: a tray having a firstproduct receiving structure of multiple portions and a second productreceiving structure of multiple portions, the multiple portions of saidfirst receiving structure being distributed among the multiple portionsof said second receiving structure.
 2. The system of claim 1 wherein:said first product receiving structure being structured and dimensionedto engage a first product at a top surface thereof and said secondproduct receiving structure being structured and dimensioned to engage asecond product at a bottom surface thereof.
 3. The system of claim 1wherein: said first product receiving structure being structured anddimensioned to engage a first product when the first product is in aninverted position and said second product receiving structure beingstructured and dimensioned to engage a second product when the secondproduct is in an upright position.
 4. The system of claim 3 wherein:said first product receiving structure being structured and dimensionedto engage the second product when the second product is in an invertedposition and said second product receiving structure being structuredand dimensioned to engage the first product when the first product is inan upright position.
 5. A reuseable packaging system for multiple itemsof similar shape comprising: a plurality of trays, each tray having atop surface with a first receiving structure to enable the receipt of afirst item when the first item is disposed in a first position and asecond receiving structure to enable the receipt of a second item whenthe second item is disposed in a second position, each of said first andsaid second receiving structures having a plurality of portions, andsaid plurality of portions of said first receiving structure aredistributed among said plurality of portions of said second receivingstructure; said plurality of trays being structured and dimensioned tobe stackable after being loaded with the first and the second items andwherein the trays are structured and dimensioned to be supported in astack by the first and second items when said reusable packaging systemis used to transport the items; and said plurality of trays beingstructured and dimensioned to be nestable when said trays aretransported without items.
 6. The system as claimed in claim 5 wherein:said first receiving structure includes recesses; and said secondreceiving structure includes mounds.
 7. The system as claimed in claim 6wherein: said first receiving structure includes a group of fiverecesses; and said second receiving structure includes a group of onerecess and four mounds.
 8. The system as claimed in claim 7 wherein:each tray of said plurality of trays is generally the same size; and abottom tray of a stack of trays is structured and dimensioned to befastened to a pallet.
 9. The system as claimed in claim 5 wherein: eachtray of said plurality of trays is generally the same size as asupporting pallet.
 10. The system as claimed in claim 5 wherein: saidfirst receiving structure is structured and dimensioned differently fromsaid second receiving structure.
 11. The system as claimed in claim 5including: a pallet; and wherein a bottom tray of a stack of saidplurality of trays is mounted to said pallet.
 12. The system as claimedin claim 11 wherein: the items to be received are chair bases; and saidplurality of trays is stackable on said pallet; and including materialadapted to wrap said stackable plurality of trays and items receivableby said trays.
 13. The system as claimed in claim 12 wherein: saidstackable plurality of trays comprises six to eight trays with mountedchair bases.
 14. The system as claimed in claim 11 wherein: saidplurality of trays are stackable in a nested disposition on said palletwhen said trays are empty.
 15. The system as claimed in claim 14wherein: said plurality of nested trays are stackable about twenty trayshigh.
 16. The system as claimed in claim 15 including: a plywood sheetadapted to be mounted to an uppermost tray of said stackable trays andsaid plywood is adapted to be wrapped with said stackable trays.
 17. Thesystem as claimed in claim 10 including: a plurality of first receivingstructures arranged in a triangular configuration.
 18. The system asclaimed in claim 17 wherein: a receiving structure of said plurality offirst receiving structures is rotationally misaligned in relation toother receiving structures of said plurality of first receivingstructures.
 19. The system as claimed in claim 6 including: cushionstrips positioned in selected recesses of said first receivingstructure.
 20. A reusable packaging system comprising: a first supportstructure having a top surface and a bottom surface; said top surface ofsaid first support structure having a first array of receivingstructures to enable receipt of a first group of products to be packagedin an inverted position and a second array of receiving structures toenable receipt of a second group of products to be packaged in anupright position, the first array of receiving structures beingdistributed among the second array of receiving structures; said bottomsurface of said first support structure being structured and dimensionedto enable engagement with a group of products to be packaged disposed inthe inverted position and with a second group of products to be packageddisposed in the upright position; and a second support structureessentially identical to said first support structure and positionedabove said first support structure, said second support structure havingtop and bottom surfaces; said top surface of said second supportstructure having a first array of receiving structures to enable receiptof a third group of products to be packaged in an inverted position anda second array of receiving structures to enable receipt of a fourthgroup of products to be packaged in an upright position; said bottomsurface of said second support structure being structured anddimensioned to enable engagement with the first group of products to bedisposed in the inverted position on said first support structure andwith the second group of products to be disposed in the upright positionon said first support structure; and said second support structure beingnestable in said first support structure when said first and said secondsupport structures are empty of products to be packaged.
 21. The systemof claim 20 wherein: said first support structure is a first tray; saidsecond support structure is a second tray; said first array of receivingstructures of said top surface of said first tray includes a cup shapedrecess and a plurality of radiating recesses; and said second array ofreceiving structures of said top surface of said first tray includes acup shaped recess and a plurality of surrounding mounds.